Propeller shaft

ABSTRACT

A propeller shaft includes a first shaft having a yoke at one end, a second shaft slidably connected to the other end of the first shaft, and a surface treated member which is arranged at a connecting portion, at which the first shaft and the second shaft are connected to each other, and to which surface treatment for improving slidability of the second shaft with respect to the first shaft is applied. The surface treated member is formed by a substrate which is separate from the first shaft and the second shaft and to which the surface treatment has been applied. The surface treated member is arranged at the connecting portion, at which the first shaft and the second shaft are connected to each other, after the surface treatment is applied.

INCORPORATION BY REFERENCE

This is a Divisional of application Ser. No. 12/959,660, filed Dec. 3,2010, and claims priority to Japanese Patent Application No. 2009-280782filed on Dec. 10, 2009. The prior applications, including thespecifications, drawings and abstract are incorporated herein byreference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a propeller shaft used as a driving forcetransmitting shaft portion of a vehicle.

2. Description of the Related Art

Japanese Patent Application Publication No. 2007-177955(JP-A-2007-177955) and Japanese Patent Application Publication No.2009-107415 (JP-A-2009-107415), for example, describe a conventionalpropeller shaft. This propeller shaft is arranged between a transmissionthat is connected to a power unit, and a differential gear that isconnected to wheels. The propeller shaft transmits output from thetransmission to the differential gear. The position of the transmissionrelative to the differential gear changes according to impacts from theroad surface and the operating state of the vehicle and the like.Therefore, in order to absorb relative displacement of these devices inthe longitudinal direction of the vehicle in particular, the propellershaft is formed of a first shaft having male splines and a second shafthaving female splines. The male splines and the female splines areformed so as to be slidable relative to each other in the axialdirection (i.e., the longitudinal direction of the vehicle).

With this kind of propeller shaft, the slide resistance between the malesplines and the female splines is large. A phenomenon known asstick-slip may occur due to relative movement between the transmissionand the differential when the vehicle is accelerating or decelerating orthe like. Stick-slip is a phenomenon in which the male splines of thefirst shaft and the female splines of the second shaft intermittentlyslide relative to each other in the axial direction.

Therefore, JP-A-2007-177955 describes coating the sliding surfaces ofthe male splines and the female splines with a solid lubrication film ofdiamond-like carbon (hereinafter also referred to as “DLC”) or the likein order to reduce the occurrence of stick-slip.

This DLC film is described in Japanese Patent Application PublicationNo, 2009-35584 (JP-A-2009-35584), for example. The DLC film is formed onthe surface of a substrate using any of a variety of known film formingmethods such as a plasma Chemical Vapor Deposition (CVD) method or aPhysical Vapor Deposition (PVD) method such as a vacuum depositionmethod. Among these film forming methods, a direct-current plasma CVDmethod is generally well used because the film forming conditions areeasy to control.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a propeller shaft withwhich the cost of surface treatment applied to reduce the occurrence ofstick-slip is lowered.

One aspect of the invention relates to a propeller shaft that includes afirst shaft having a yoke at one end, a second shaft slidably connectedto the other end of the first shaft, and a surface treated member whichis arranged at a connecting portion, at which the first shaft and thesecond shaft are connected to each other, and to which surface treatmentfor improving slidability of the second shaft with respect to the firstshaft is applied. The surface treated member is formed of a substratewhich is separate from the first shaft and the second shaft and to whichthe surface treatment is applied. The surface treated member is arrangedat the connecting portion, at which the first shaft and the second shaftare connected to each other, after the surface treatment has beenapplied.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and further features and advantages of the invention willbecome apparent from the following description of example embodimentswith reference to the accompanying drawings, wherein like numerals areused to represent like elements and wherein:

FIG. 1 is a front partial sectional view of a propeller shaft accordingto a first example embodiment of the invention;

FIG. 2 is a view of a state in which a first shaft and a surface treatedmember are to be joined by friction welding according to the firstexample embodiment;

FIG. 3 is a front partial sectional view of the first shaft and thesurface treated member that have been integrated by friction weldingaccording to the first example embodiment;

FIG. 4A is a view of a state in which a first shaft and a surfacetreated member are fixed together by press fitting according to a secondexample embodiment;

FIG. 4B is a partial sectional view taken along the line A-A in FIG. 4A;

FIG. 4C is a partial sectional view taken along the line B-B in FIG. 4A;

FIG. 5 is a front partial sectional view of the first shaft and thesurface treated member that have been integrated by press fittingaccording to the second example embodiment;

FIG. 6 is a front partial sectional view of a propeller shaft accordingto a third example embodiment;

FIG. 7 is a perspective view of a surface treated member arranged at aportion corresponding to line C-C in FIG. 6;

FIG. 8 is a sectional view of a main portion of a propeller shaftaccording to a fourth example embodiment;

FIG. 9 is a sectional view of a main portion of a propeller shaftaccording to a first modified example; and

FIG. 10 is a sectional view of a main portion of a propeller shaftaccording to a second modified example.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, propeller shafts according to example embodiments of theinvention will be described with reference to the accompanying drawings.

Hereafter, a first example embodiment will be described. A propellershaft according to the first example embodiment will be described withreference to FIGS. 1 to 3. FIG. 1 is a front partial sectional view of apropeller shaft 1 according to the first example embodiment. In FIG. 1,the left side portion above the shaft axis is shown in a sectional view.FIG. 2 is a view of a state in which a first shaft and a surface treatedmember are to be joined by friction welding. FIG. 3 is a front partialsectional view of the first shaft and the surface treated member thathave been integrated by friction welding. Note that, in the followingdescription, unless otherwise stated, “right” refers to the right inFIG. 1 and “left” refers to the left in FIG. 1.

The propeller shaft 1 is a shaft for transmitting power from an engineto a differential unit. This propeller shaft 1 may be a front propellershaft or a rear propeller shaft depending on the drive system. In eithercase, the propeller shaft connects the engine to the differential unitand is arranged extending in the longitudinal direction of the vehicle.

The propeller shaft 1 in this example embodiment has a first shaft 10that has male splines (hereinafter referred to as “second splines”) 31and a second shaft 20 that has female splines (hereinafter referred toas “first splines”) 23, as shown in FIG. 1. The second shaft 20 isarranged so as to be slidable in the axial direction with respect to thefirst shaft 10. A surface treated member 30 is fixed to the first shaft10 by friction welding.

The first shaft 10 has a first joint portion 11 that forms a yoke of auniversal joint, and a cylindrical portion 12 that is integrally formedwith a bottom portion (i.e., the right end) of the first joint portion11 and arranged coaxially with the shaft axis. A seal portion 14 isprovided on the outer peripheral surface of the first joint portion11-side end portion (i.e., the left end portion) of the cylindricalportion 12. The seal portion 14 has a ring-shaped groove 13 formed inthe outer peripheral surface of the cylindrical portion 12, and a sealrubber (not shown) fitted into the groove 13.

The second shaft 20 has a first tube portion 21 positioned in a centerportion in the axial direction (hereinafter simply referred to as the“axial center portion”), a second tube portion 22 that is coupled to aleft end surface of the first tube portion 21, first splines 23, and asecond joint portion 24 that is coupled to a right end surface of thefirst tube portion 21.

The first tube portion 21 is formed in a cylindrical shape and has alarge diameter portion with a diameter larger than the diameters of bothend portions, at the axial center portion. The second tube portion 22 isalso formed in a cylindrical shape, and the end surface of a right sideend portion 22 a of this second tube portion 22 is coupled by frictionwelding to the end surface a left side end portion of the first tubeportion 21. The left side end portion of the first tube portion 21 isformed in the same diameter as the right side end portion 22 a of thesecond tube portion 22. The majority of the left side portion of thesecond tube portion 22, excluding the right side end portion 22 a, is asmall diameter cylindrical portion 22 b that has an outer diametersmaller than that of the right side end portion 22 a. The outerperipheral surface of the small diameter cylindrical portion 22 b isformed such that the outer diameter of the small diameter cylindricalportion 22 b is constant in the axial direction. A balance weightportion 22 e is formed in substantially the center portion of the smalldiameter cylindrical portion 22 b in the axial direction.

The left end portion of this small diameter cylindrical portion 22 b isfitted to the seal portion 14 provided on the outer peripheral surfaceof the cylindrical portion 12 of the first shaft 10. That is, the smalldiameter cylindrical portion 22 b is arranged in a state in which theinner peripheral surface of the small diameter cylindrical portion 22 babuts against the outer peripheral surface of the seal rubber of theseal portion 14. As a result, a seal function is exhibited by the sealrubber sliding on the outer peripheral surface of the cylindricalportion 12 of the first shaft 10 when the first shaft 10 and the secondshaft 20 slide relative to each other in the axial direction.

The first splines 23 are integrally formed in the inner peripheralsurface of the small diameter cylindrical portion 22 b of the secondtube portion 22. These first splines 23 are formed, from the axialcenter portion toward the right side end, in the inner peripheralsurface of the small diameter cylindrical portion 22 b. The area inwhich the first splines 23 are formed is larger in the axial directionthan an area W1 in which the second splines 31 are formed in the outerperipheral surface of the surface treated member 30.

The second joint portion 24 forms a yoke of a universal joint and isjoined to a right end surface of the first tube portion 21 by frictionwelding.

The surface treated member 30 is formed in a cylindrical shape havingthe same inner diameter as the cylindrical portion 12 of the first shaft10. The left end surface of the surface treated member 30 is joined tothe right end surface of the cylindrical portion 12 by friction welding.The second splines 31 are integrally formed in the outer peripheralsurface of the majority of the right side portion of the surface treatedmember 30, excluding the left side end portion. Note, the area in whichthe second splines 31 are formed in the axial direction in the surfacetreated member 30 is denoted by reference character W1, and is shorterthan the area in which the first splines 23 are formed in the axialdirection. The tip diameter of the second splines 31 is substantiallythe same as the root diameter of the first splines 23, and the rootdiameter of the second splines 31 is substantially the same as the tipdiameter of the first splines 23. Also, these second splines 31 arearranged so as to axially slidably engage with the first splines 23. Asa result, the first shaft 10 and the second shaft 20 are axiallyslidably connected together by the second splines 31 being engaged withthe first splines 23.

A DLC film (i.e., a solid lubrication film) 32 is formed on the surfaceportion of the second splines 31 of the surface treated member 30 by aconventionally known direct-current plasma CVD method in order to reducestick-slip that tends to occur when the second splines 31 slide againstthe first splines 23. With this example embodiment, the DLC film 32 isformed on an independent substrate that is separate from the first shaft10, before the surface treated member 30 is joined to the first shaft 10by friction welding.

In this example embodiment, first, a substrate having a predeterminedshape that forms the second splines 31 is prepared as the surfacetreated member 30. Here, the prepared substrate has a bulging portion 30a with a diameter that is larger than the outer diameter when the partis finished, on an end portion in the axial direction (hereinaftersimply referred to as “axial end portion”) that is joined to the firstshaft 10 by friction welding after the surface treatment is complete, asshown in FIG. 2. An axial end portion of the first shaft 10 that isjoined to the surface treated member 30 has a similar bulging portion 12a. That is, the bulging portions 30 a and 12 a that have diameters thatare larger than the outer diameter when the part is finished are formedon the axial end portions of the substrate (i.e., the surface treatedmember 30) and the first shaft 10, respectively. Note that, thesebulging portions 30 a and 12 a are removed together with burr producedby friction welding, during a deburring process that is applied afterfriction welding.

Next, the surface of the portion other than the portion where the DLCfilm 32 is formed (i.e., other than the sliding surface of the secondsplines 31) is masked, and the substrate is placed inside a plasmareaction chamber that is used as a treatment furnace. At this time, thesubstrate to which the surface treatment is applied is approximately thesame size as the first shaft 10, and therefore approximately one-halfthe size of a member formed by integrating the surface treated member 30and the first shaft 10 with each other. Therefore, a large number, i.e.,approximately twice the conventional number, of substrates are able tobe placed inside the plasma reaction chamber, so surface treatment isable to be applied to even more substrates at once.

Then, a chemical vapor deposition process is performed by applying avoltage of several hundred volts and continuously discharging directcurrent for a predetermined period of time between a positive electrodeand a negative electrode provided inside the plasma reaction chamber, ina state where the pressure in the plasma reaction chamber is apredetermined pressure and the atmosphere in the plasma reaction chamberis the gas atmosphere. As a result, the DLC film 32 with a filmthickness of approximately 5±4 μm is formed on the surface of the secondsplines 31 of the substrate.

After the surface treatment of the surface treated member 30 is finishedin this way, the surface treated member 30 and the first shaft 10 arefriction pressure welded using a known friction welding machine, asshown in FIG. 2. As a result, the axial end surfaces of these are joinedtogether. At this time, burr protruding radially outward is produced atthe joint as a result of the friction welding of the surface treatedmember 30 and the first shaft 10. A deburring process according to aturning process or the like is applied after friction welding isfinished (see the broken line portion in FIG. 3). In this deburringprocess, the bulging portions 30 a and 12 a formed on the axial endportions of the surface treated member 30 and the first shaft 10,respectively, are removed together with burr produced by the frictionwelding.

The surface treated member 30 of the propeller shaft 1 of this exampleembodiment structured as described above is formed of a member that isseparate from the first shaft 10 and the second shaft 20. The surfacetreatment that is applied to reduce the occurrence of stick-slip isapplied only to the surface treated member 30. Therefore, the volume ofthe surface treated member 30 can be reduced, which makes it possible tofit more substrates inside the treatment furnace when applying thesurface treatment of the surface treated members 30. As a result, thesurface treatment can be applied to even more surface treated members 30at once, so treatment efficiency can be improved, which enables thesurface treatment cost to be significantly reduced.

In particular, in this example embodiment, the surface treatment appliedto the surface treated member 30 employs a direct-current plasma CVDmethod that is performed with the substrate with the surface on whichthe DLC film 32 is to be formed placed inside a plasma reaction chamberthat serves as the treatment furnace. Accordingly, more substrates canbe placed inside the plasma reaction chamber. Thus, the DLC film 32 canbe efficiently formed on more substrates at once, so a more significantreduction in the surface treatment cost can be achieved.

In this example embodiment, the first shaft 10 and the second shaft 20are connected by engaging the second splines 31 formed in the surfacetreated member 30 with the first splines 23 formed in the second shaft20. Accordingly, the size of the surface treated member 30 can bereduced to a size that approximately corresponds to the length of thesecond splines 31. As a result, treatment efficiency of the surfacetreatment can be improved, so the surface treatment cost can besignificantly reduced.

In this example embodiment, the surface treated member 30 and the firstshaft 10 are joined together at the axial end surfaces by frictionwelding. Therefore, the surface treated member 30 and the first shaft 10are strongly coupled together. Also, the axis of the surface treatedmember 30 and the axis of the first shaft 10 are aligned with each otherrelatively easily by appropriately controlling the conditions of thefriction welding.

In this example embodiment, before the friction welding, the axial endportions of the surface treated member 30 and the seat portion 10, whichare joined together by friction welding, have the bulging portions 30 aand 12 a that have diameters that are larger than the outer diameterwhen the part is finished. The bulging portions 30 a and 12 a areremoved together with burr produced by the friction welding, during thedeburring process that is applied after friction welding. Therefore,large friction welding surfaces of the surface treated member 30 and thefirst shaft 10 are ensured during friction welding. As a result, thesurface treated member 30 and the first shaft 10 are more stronglyjoined together.

Note that, in this example embodiment, the surface treated member 30 isconnected to the first shaft 10, but it may also be structured to beconnected to the second shaft 20. Also, in this example embodiment, thefirst splines 23 that are female splines are formed in the second shaft20, and the second splines 31 that are male splines are formed in thesurface treated member 30. However, female splines may be formed in thesurface treated member 30 and male splines may be formed in the secondshaft 20.

Hereafter, a second embodiment of the invention will be described. Apropeller shaft according to a second example embodiment will now bedescribed with reference to FIGS. 4 and 5. FIG. 4A is a view of a statein which a first shaft and a surface treated member are to be fixedtogether by press fitting according to the second example embodiment.FIG. 4B is a partial sectional view taken along the line A-A in FIG. 4A.FIG. 4C is a partial sectional view taken along the line B-B in FIG. 4A.FIG. 5 is a front partial sectional view of the first shaft and thesurface treated member that have been integrated by press fittingaccording to the second example embodiment.

With the propeller shaft according to the first example embodiment, thesurface treated member 30 and the first shaft 10 are joined together atthe axial end surfaces by friction welding. The propeller shaftaccording the second example embodiment differs from the propeller shaftaccording to the first example embodiment in that a surface treatedmember 30A and a first shaft 10A are fixed together by being press fitin the axial direction. Therefore, structure and members that are thesame as those in the first example embodiment will be denoted by thesame reference characters as those in the first example embodiment, anddetailed descriptions thereof will be omitted. The following descriptionwill focus on the differences.

The first shaft 10A of the second example embodiment has a first jointportion 11A that forms a yoke of a universal joint, and a cylindricalportion 12A that is integrally formed with a bottom portion (i.e., theright end) of the first joint portion 11A and arranged coaxially withthe shaft axis.

The first joint portion 11A is the same as the first joint portion 11 ofthe first example embodiment. The left side end portion of thecylindrical portion 12A has a seal portion 14A formed of a groove 13Aand a seal rubber (not shown), as in the cylindrical portion 12 of thefirst example embodiment. This cylindrical portion 12A is longer in theaxial direction than the cylindrical portion 12 of the first exampleembodiment. That is, the cylindrical portion 12A is longer than thecylindrical portion 12 by the axial length of the surface treated member30 that has been joined to the right side end surface of the cylindricalportion 12 in the first example embodiment. Accordingly, the axiallength of the first shaft 10A is approximately the same as the axiallength of the member formed by integrating the first shaft 10 and thesurface treated member 30 with each other by friction welding in thefirst example embodiment.

A fit portion 16A, to which the surface treated member 30A is fitted, isformed in a portion of the cylindrical portion 12A, which extends fromsubstantially the axial center to the right end of the cylindricalportion 12A. This fit portion 16A has an inner diameter that is the sameas the inner diameter of the left side portion of the cylindricalportion 12A, and has an outer diameter that is smaller than the outerdiameter of the left side portion. Fourth splines 17A that are malesplines are formed in the outer peripheral surface of the fit portion16A, as shown in FIG. 4B.

The surface treated member 30A is formed in a cylindrical shape and hassubstantially the same length as the axial length of the fit portion 16Aof the cylindrical portion 12A. Third splines 33A that are femalesplines are formed in the inner peripheral surface of the surfacetreated member 30A, as shown in FIG. 4C. The tip diameter of the thirdsplines 33A is slightly smaller than the root diameter of the fourthsplines 17A, and the root diameter of the third splines 33A is slightlysmaller than the tip diameter of the fourth splines 17A. As a result, asshown in FIG. 4A, when the surface treated member 30A is press fit inthe axial direction onto the outer peripheral side of the fit portion16A of the cylindrical portion 12A, the third splines 33A engage withthe fourth splines 17A. Accordingly, relative movements between thesurface treated member 30A and the cylindrical portion 12A in the axialdirection and the circumferential direction are strongly restricted.

Also, second splines 31A that are similar to the second splines 31 inthe first example embodiment are formed along the entire length in theaxial direction in the outer peripheral surface of the surface treatedmember 30A. A DLC film 32A with a film thickness of approximately 5±4 μmis formed on the surface of these second splines 31A by applying asurface treatment to the surface of the second splines 31A, which issimilar to the surface treatment applied to the surface of the secondsplines 31 in the first example embodiment. These second splines 31Aengage with first splines (not shown) formed in a second shaft (notshown), as in the first example embodiment. As a result, the first shaft10A and the second shaft are axially slidably connected together by thesecond splines 31A being engaged with the first splines.

In the propeller shaft of this example embodiment structured asdescribed above, the surface treated member 30A and the first shaft 10Aare fixed together by press fitting in the axial direction. Accordingly,the surface treated member 30A and the first shaft 10A are integrated bybeing strongly fixed together. In this case, the surface treated member30A is fixed to the first shaft 10A by being axially press fit onto thefirst shaft 10A. As a result, the axis of the surface treated member 30Aand the axis of the first shaft 10A are easily aligned with each other.

In this example embodiment, the surface treated member 30A has the thirdsplines 33A in one of the inner peripheral surface and the outerperipheral surface while having the second splines 31A in the other ofthe inner peripheral surface and the outer peripheral surface, and thefirst shaft 10A has the fourth splines 17A. The surface treated member30A and the first shaft 10A are fixed together by engaging the thirdsplines 33A with the fourth splines 17A. Therefore, the surface treatedmember 30A and the first shaft 10A are fixed together by both pressfitting and spline-engagement, so the surface treated member 30A and thefirst shaft 10A are strongly fixed together without slipping out ofposition even when torque is transmitted.

In this example embodiment, the fourth splines 17A that engage with thethird splines 33A are formed in the first shaft 10A, but the fourthsplines 17A may also be formed in the second shaft 20. The third splines33A are formed in the inner peripheral surface on the side opposite thesecond splines 31A that are formed in the outer peripheral surface ofthe surface treated member 30A. If the second splines 31A are formed inthe inner peripheral surface of the surface treated member 30A, then thethird splines 33A are formed in the outer peripheral surface of thesurface treated member 30A.

Hereafter, a third example embodiment will be described. A propellershaft 2 according to a third example embodiment will now be describedwith reference to FIGS. 6 and 7. FIG. 6 is a front partial sectionalview of the propeller shaft according to the third example embodiment.FIG. 7 is a perspective view of a surface treated member arranged at aportion corresponding to the line C-C in FIG. 6.

The propeller shaft 2 in this example embodiment has a first shaft 10Bwith fifth splines 15B, a second shaft 20B with sixth splines 23B, and asurface treated member 30B that is formed in a plate shape and arrangedon sliding surfaces of the first shaft 10B and the second shaft 20B, asshown in FIGS. 6 and 7.

The first shaft 10B has a first joint portion 11B and a cylindricalportion 12B, as in the first example embodiment. The first joint portion11B is formed in a manner similar to that in which the first jointportion 11 in the first example embodiment is formed. The cylindricalportion 12B has substantially the same length in the axial direction asthe cylindrical portion 12A of the second example embodiment. A sealportion 14B formed of a groove and a seal rubber (neither of which isshown) is provided on the outer peripheral surface of the first jointportion 11B-side end portion (i.e., the left end portion) of thecylindrical portion 12B, as in the first example embodiment.

The fifth splines 15B that are structured like the second splines 31formed in the outer peripheral surface of the surface treated member 30in the first example embodiment are formed in the outer peripheralsurface of a portion of the cylindrical portion 12B, which extends fromsubstantially the axial center to the right end of the cylindricalportion 12B. However, the DLC film 32 that is formed on the surface ofthe second splines 31 is not formed on the surface of the fifth splines15B. The area in which the fifth splines 15B are formed in the axialdirection on the first shaft 10B is denoted by reference character W2,and is shorter than the area in which the sixth splines 23B are formedin the axial direction.

The second shaft 20B is structured like the second shaft 20 of the firstexample embodiment, and has a first tube portion 21B, a second tubeportion 22B, sixth splines 23B, and a second joint portion 24B. Thesixth splines 238 of the third example embodiment correspond to thefirst splines 23 of the first example embodiment. The tip diameter ofthese sixth splines 23B is substantially the same as the root diameterof the fifth splines 15B, and the root diameter of these sixth splines23B is substantially the same as the tip diameter of the fifth splines15B. Also, these sixth splines 23B are arranged so as to axiallyslidably engage with the fifth splines 15B. As a result, the first shaft10B and the second shaft 20B are axially slidably connected together bythe fifth splines 15B being engaged with the sixth splines 23B.

The structure other than the sixth splines 23B of the second shaft 20Bis the same as that in the first example embodiment, so a descriptionthereof will be omitted.

The surface treated member 30B is formed in a plate shape of apredetermined thickness (approximately 0.01 to 0.2 mm). Surfacetreatment similar to the surface treatment applied to the surfacetreated member 30 of the first example embodiment is applied to onesurface of the surface treated member 30B. That is, a DLC film 32B witha film thickness of 5±4 μm is formed on one surface of the surfacetreated member 30B. This surface treated member 30B is arranged onsliding surfaces of the fifth splines 15B and the sixth splines 23B.

In this example embodiment, as shown in FIG. 7, the other surface of thesurface treated member 30B (i.e., the surface on which the DLC film 32Bis not formed) is adhered by an adhesive to a positive torque loadsurface 16B that is toward the front, with respect to forward rotation,of each of the teeth of the fifth splines 15B. In this case, the surfacetreated member 30B is formed in a rectangle that is smaller than thepositive torque load surface 16B, and is arranged only at a centerportion that excludes the outer peripheral edge portion of the positivetorque load surface 16B. As a result, the surface (i.e., the onesurface) of the surface treated member 30B, on which the DLC film 32B isformed, faces a positive torque load surface (not shown) of the sixthsplines 23B that face the positive torque load surface 16B of the fifthsplines 15B. As a result, good slidability in the axial directionbetween the fifth splines 15B and the sixth splines 23B is ensured.

In the propeller shaft 2 of the third example embodiment structured asdescribed above, the surface treated member 30B is formed in a plateshape and arranged on the sliding surfaces of the fifth splines 15B andthe sixth splines 23B. Therefore, because the surface treated member 30Bneed only be formed in a plate shape of a size that approximatelycorresponds to each of the sliding surfaces of the fifth splines 15B andthe sixth splines 23B, the surface treated member 30B can be madeextremely small. Thus, treatment efficiency when applying the surfacetreatment for forming the DLC film 32B to the surface of the substrateis even further improved, so more significant reductions in the surfacetreatment cost and the logistics cost can be achieved.

Also, in the third example embodiment, the surface treated member 3013is adhered to the positive torque load surface 16B of the slidingsurface of the fifth splines 15B. As a result, stick-slip that tends tooccur at the positive torque load surfaces of the sliding surfaces ofthe fifth splines 15B and the sixth splines 23B is effectively reduced.

In the third example embodiment, the surface treated member 30B isadhered to the sliding surface of each of the fifth splines 15B.Alternatively, the surface treated member 30B may be adhered to thesliding surface of each of the sixth splines 23B.

A fourth embodiment of the invention will be described. Next, apropeller shaft according to a fourth example embodiment will bedescribed with reference to FIG. 8. FIG. 8 is a sectional view of a mainportion (i.e., a portion corresponding to line C-C in FIG. 6) of thepropeller shaft according to the fourth example embodiment.

In the propeller shaft according to the third example embodiment, thesurface treated member 30B formed in a plate shape is adhered to eitherthe sliding surface of each of the fifth splines 15B or the slidingsurface of each of the sixth splines 23B. In contrast, in the propellershaft according to the fourth example embodiment, a surface treatedmember 30C formed in a round bar shape is arranged, so as to be able totransmit torque, between a surface of seventh splines 15C formed in afirst shaft (not shown) and a surface of eighth splines 23C formed in asecond shaft (not shown). The fourth embodiment differs from the thirdexample embodiment in this point, and this difference will hereinafterbe described.

In the fourth example embodiment, the seventh splines 15C and the eighthsplines 23C are arranged such that projections 41C and 51C face oneanother in the radial direction and recesses 42C and 52C face oneanother in the radial direction. The recesses 42C and 52C are formedsuch that their widths gradually increase from the bottom side towardthe open side. Accordingly, a space 40C that extends in the axialdirection and has a generally hexagonal cross section is formed at aportion where the recesses 42C and 52C face one another. At two recesses42C and 52C that define the space 40C, the distance between bottomsurfaces 43C and 53C that face one other while the recesses 42C and 52Care substantially parallel is greater than the distance between sidefaces (i.e., torque transmitting surfaces) 44C and 54C that face oneanother while the recesses 42C and 52C are parallel.

Also, the long surface treated member 30C that has a circular crosssection and is formed so as to be approximately the same length as theaxial lengths of the seventh splines 15C and the eighth splines 23C isarranged in each space 40C. In this case, the surface treated member 30Cis arranged in a state in which the outer peripheral surface thereofcontacts the side faces 44C and 54C that face one another while therecesses 42C and 52C that define the space 40C are parallel. A DLC 32Cwith a film thickness of approximately 5±4 μm is formed on the surfaceof this surface treated member 30C by applying a surface treatment tothe surface of this surface treated member 30C, which is similar to thesurface treatment applied to the surface treated member 30 of the firstexample embodiment.

In the propeller shaft of the fourth example embodiment structured asdescribed above, the surface treated member 30C is arranged between theside faces 44C and 54C (i.e., the torque transmitting surfaces) of theopposing recesses 42C and 52C of the seventh splines 15C and the eighthsplines 23C. Therefore, appropriate dimensions between the opposingtorque transmitting surfaces 44C and 54C of the seventh splines 15C andthe eighth splines 23C is ensured by appropriately setting the diameterof the surface treated member 30C. Also, arranging the surface treatedmember 30C in the space 40C defined and formed by the torquetransmitting surfaces 44C and 54C make it possible to suppress adecrease in the flexural rigidity and durability of the propeller shaft.

Hereafter, a first modified example will be described. FIG. 9 is asectional view of a main portion of a propeller shaft according to afirst modified example of the fourth example embodiment. This firstmodified example uses a surface treated member 30D with a rectangularcross section instead of the surface treated member 30C with a circularcross section that is used in the fourth example embodiment. In thisfirst modified example, seventh splines 15D and eighth splines 23D haveprojections 41D and 51D and recesses 42D and 52D. The projections 41Dand 51D face the recesses 52D and 42D, respectively, in the radialdirection. Also, the seventh splines 15D and the eighth splines 23D arearranged such that the projections 41D and 51D fit inside the recesses52D and 42D such that a predetermined clearance is left therebetween. Inthis case, top surfaces 45D and 55D of the projections 41D and 51D andbottom surfaces 53D and 43D of the recesses 52D and 42D face each otherwith a predetermined clearance left therebetween. Side faces (i.e.,torque transmitting surfaces) 44D and 54D of the projections 41D and 51Dthat are consecutive in the circumferential direction face one anotherwith a predetermined clearance left therebetween.

Also, the long surface treated member 30D that has a rectangular crosssection and has approximately the same length as the axial lengths ofthe seventh splines 15D and the eighth splines 23D is arranged in eachspace 40D formed between opposing side faces (i.e., torque transmittingsurfaces) 44D and 54D of the projections 41D and 51D that areconsecutive in the circumferential direction.

The same effects as those described above are obtained with the firstmodified example structured as described above.

Hereafter, a second modified example will be described. FIG. 10 is asectional view of a main portion of a propeller shaft according to asecond modified example of the fourth example embodiment. This secondmodified example uses a surface treated member 30E with a U-shaped crosssection instead of the surface treated member 30D with a rectangularcross section that is used in the first modified example. This surfacetreated member 30E has a predetermined thickness and is formed to havethe same length as the surface treated member 30D of the first modifiedexample. This surface treated member 30E is arranged over a space formedbetween opposing side faces (i.e., torque transmitting surfaces) 44E and54E of projections 41E and 51E that are consecutive in thecircumferential direction, and a space formed between top surfaces 45Eand 55E of the projections 41E and 51E, and bottom surfaces 53E and 43Eof recesses 52E and 42E.

The same effects as those described above are obtained with the secondmodified example structured as described above.

In addition, if serrations are used instead of splines, it is possibleto obtain the same effects as those obtained when the splines are used.

1. A manufacturing method for a propeller shaft in which a first shafthas a yoke at one end, a second shaft is slidably connected to the otherend of the first shaft, and a surface treated member which is arrangedat a connecting portion at which the first shaft and the second shaftare connected to each other, and to which surface treatment forimproving slidability of the second shaft with respect to the firstshaft is applied, wherein: the surface treated member is formed of asubstrate which is separate from the first shaft and the second shaftand to which the surface treatment is applied; and the surface treatedmember is arranged at the connecting portion at which the first shaftand the second shaft are connected to each other, after the surfacetreatment is applied.
 2. The method according to claim 1, wherein thesurface treated member has a solid lubrication film that is formed on asurface of the substrate by a Physical Vapor Deposition method or aChemical vapor Deposition method as the surface treatment.
 3. The methodaccording to claim 1, wherein one of the first shaft and the secondshaft has first splines; wherein the surface treated member is fixed tothe other of the first shaft and the second shaft, and has secondsplines to which the surface treatment is applied, and wherein the firstshaft and the second shaft are connected to each other by slidablyengaging the first splines and the second splines with each other. 4.The method according to claim 3, wherein the surface treated member andthe other of the first shaft and the second shaft are joined at axialend surfaces by friction welding.
 5. The method according to claim 4,wherein before friction welding, each of an axial end portion of thesurface treated member and an axial end portion of the other of thefirst shaft and the second shaft, the axial end portions being joined byfriction welding, has a bulging portion that has an outer diameterlarger than an outer diameter at a time of part completion, wherein thebulging portion is removed together with burr produced by frictionwelding, during a deburring process that is applied after frictionwelding.
 6. The method according to claim 3, wherein the surface treatedmember and the other of the first shaft and the second shaft are fixedto each other by press fitting.
 7. The method according to claim 6,wherein the surface treated member has third splines in one of an innerperipheral surface and an outer peripheral surface while having thesecond splines in the other of the inner peripheral surface and theouter peripheral surface, wherein the other of the first shaft and thesecond shaft has fourth splines, and wherein the surface treated memberand the other of the first shaft and the second shaft are fixed to eachother by engaging the third splines and the fourth splines with eachother.
 8. The method according to claim 1, wherein the first shaft andthe second shaft are connected to each other by engaging fifth splinesformed in the first shaft and sixth splines formed in the second shaftwith each other, and wherein the surface treated member is formed in aplate shape, has at least one surface to which the surface treatment isapplied, is adhered to a sliding surface of one of the fifth splines andthe sixth splines, and slides at the surface, to which the surfacetreatment is applied, with respect to a sliding surface of the other ofthe fifth splines and the sixth splines.
 9. The method according toclaim 8, wherein the surface treated member is adhered to a positivetorque load surface of the sliding surface of one of the fifth splinesand the sixth splines.
 10. The method according to claim 1, wherein thefirst shaft has seventh splines; wherein the second shaft has eighthsplines; and wherein the surface treated member is formed long andarranged, so as to be able to transmit torque, between surfaces of theseventh splines and the eighth splines, the surfaces facing one another.11. The method according to claim 10, wherein a sectional shape of thesurface treated member in a direction orthogonal to a length directionof the surface treated is circular, rectangular, or oddly-shaped.